ahsan choudhuri, ph.d. ... ahsan choudhuri, ph.d. professor and chair, department of mechanical...

Ahsan Choudhuri, Ph.D. Professor and Chair, Department of Mechanical Engineering Mr. and Mrs. MacInstosh Murchison Chair II Professor in Engineering Director, NASA MIRO Center for Space Exploration & Technology Research University of Texas at El Paso

Ryan Wicker, Ph.D. Professor, Department of Mechanical Engineering Mr. and Mrs. MacIntosh Murchison Distinguished Chair I Professor in Engineering Director, W. M. Keck Center for 3D Innovation The University of Texas at El Paso

2015 HBCU/UCR Joint Kickoff Meeting Crosscutting Research Technology Program National Energy Technology Laboratory Department of Energy

27-28 October, 2015

Morgantown, WV

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 Project Title: METAL THREE DIMENSIONAL (3D) PRINTING OF LOW-NITROUS OXIDE (NOX) FUEL INJECTORS WITH INTEGRATED TEMPERATURE SENSORS

 Award No: DE-FE0026330  Investigators: Dr. Ahsan Choudhuri, Email: [email protected], Phone: 915-747-6905

Dr. Ryan Wicker, Email: [email protected] ,Phone: 915-747-7443  DOE Project Manager: Maria Reidpath, Email: [email protected], Phone: 304-285-4140  UTEP Business Contact: Irene Holguin, Email: [email protected], Phone: 915-747-5680  Period pf Performance: 10/01/2015-09/30/2018  Project Amount: $250,000  Research Team: Jorge Mireles and Jaime Torres  UTEP Research Centers: W. M. Keck Center for 3D Innovation

NASA MIRO Center for Space Exploration and Technology Research

mailto:[email protected] mailto:[email protected] mailto:[email protected] mailto:[email protected]

 Project Information  Objectives  Background  Technical Methods

 Task Descriptions

 Timeline  Milestone Log  Decision Points

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 Objective 1: Development of design methodologies for Low-NOx fuel injectors with embedded temperature capabilities for Electron Beam Melting (EBM) based 3D Manufacturing.

 Design for Additive Manufacturing: Component Design Features; Geometric Tolerance and Dimensioning

 Design Features; Process Parameters and Part Quality

 Objective 2: Development of optimum EBM process parameters and powder removal techniques to remove sintered powder from internal cavities and channels of Low- NOx fuel injectors with embedded temperature sensors.

 Dry ice blasting, ceramic blasting, water jetting, chemical etching, ultrasonics (patented technology by UTEP – U.S. Patent No. 8,828,311 B2), and megasonic baths

 Objective 3: Testing of the EBM fabricated Low-NOx fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory Turbine Combustor

 Functionality and operability in a realistic environment (combustor pressure up to 1.2 MPa (~175 psi) using natural gas)

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Additive manufacturing is a process of creating parts directly from a computer model in a

layer-by-layer fashion

 Seven classes of technologies

 Material Extrusion

 Material Jetting

 Binder Jetting

 Directed energy deposition

 Vat photopolymerization

 Sheet lamination

 Powder bed fusion

Scan direction

Melted Particles

High-energy beam

Melting

Deposited powder

Un-melted powder

A2

Two Build Tanks 200 x 200 x 350mm (7.8 x 7.8 x 13.75 in)

Ø = 300mm, h = 200mm (Ø = 11.81, h = 7.8 in.)

S12 (modified for high temperatures)

One Build Tank 200 x 200 x 180mm (7.8 x 7.8 x 7.0 in.)

Heat Shield

Build Table

Electron Gun

Powder Distributor

Powder Container

Optics

Filament

 Arcam Released Materials  Titanium Ti-6Al-4V

 Titanium Ti-6Al-4V ELI

 Titanium Grade 2

 Cobalt-Chrome, ASTM F75

 Research Materials  Ti-6Al-4V

 TiAl

 CoCrMo

 Rene alloys

 Inconel 625

 Inconel 718

 Copper

 Niobium

 Iron based alloys

 Other proprietary alloys

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 Sensors can be embedded (without post-production component modifications) in EBM-fabricated components through two distinct processes:

 Stop and Go of the fabrication process which allows sensor placement within a cavity during fabrication where the process is allowed to continue upon sensor placement

 Post-integration of sensors in customized compartments selectively built within the part.

 The Stop and Go process requires an extremely accurate re-alignment of the powder- bed during the restart process.

 Metallization and shorting of sensors due to a considerable high temperature of the EBM process creates significant fabrication challenges and limit the types of sensors that can be embedded.

 The Post-Integration of sensors is a practical alternative for components that can be effectively designed and fabricated with pre-built complex sensor compartments without the need for post-production component modifications.

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Embedded sensor

Sensor lead

Conductive material

Nonconductive material

Nonconductive material

Piezoceramic sensor

Partial part with pocket (Ti-6Al-4V)

Partial part with embedded sensor

(PZT/LiNbO3)

Smart part with embedded sensor

Cross section of smart part

 Metallic components with embedded piezoceramic sensor for high efficiency energy system

 Fabrication of complex structures

 Real time performance feedback from desired location

 Structural health monitoring

Pressure tube demonstration

Embedded Piezoceramic sensor

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EBM Fabricated Pintle-Injector for a 9 KN LO2/Methane Rocket Engine

LOX

LCH4

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 Certain challenges are foreseen when creating internal cavities/channels within AM parts fabricated using powder bed fusion AM technologies such as electron beam melting

 Geometric Tolerance and Dimensioning of internal cavities and channels

 Removal of powder from internal channels/cavities as the powder to be removed has been lightly sintered during the fabrication process

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 Test Component: Low-NOx fuel injector with integrated temperature sensors (derived from the Solar Turbine low-NOx fuel injector for natural gas )

 Ceramic Insulated High Temperature Thermocouple: OMEGA® Nextel/XC-14-J-12

 Inconel 718 and Inconel 625

 3.2 to 3.8 mm diameter slender circular channels

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Objective 1: Development of design methodologies of Low-NOx fuel injectors with embedded temperature capabilities for EBM based 3D Manufacturing.

Task 1.1: Fabrication of test part for technology evaluation

 parts will be fabricated (Inconel 718, Inconel 625, and/or Titanium alloys) to assess the dimensional accuracy of EBM-fabricated parts

 various geometric shapes and features that can be potentially implemented in fuel injectors.

Letter Feature Factor To be Tested

A Square base

Dimensional accuracy

B (+) Lateral ridges

C (-) Lateral ridges

D (+) Descending cylinders

E (-) Descending cylinders

F (+) Staircase

G (-) Staircase

H (+) Cylinders

I (-) Cylinders

J Ramps Surface Roughness

K Rectangular prisms Linear displacement

error

L Tensile Bar Ultimate tensile strength

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Task 1.2: Evaluation of test parts

 Dimensional accuracy

 OGP Smartscope Flash 250

 Mitutoyo SJ-201P surface roughness tester

 Mechanical testing will be completed using the specification of the E8/E8M ASTM standard

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 Task 1.3: Design for AM of Low-NOx fuel injector

 Develop designs to fabricate the complete injector (using Inconel 718, Inconel 625, and Titanium alloys) in a single EBM build run.

 The task will run in parallel to the powder removal tasks (Objective 2)

 Final design will be created upon determining the appropriate powder removal strategies

 Task 1.4: Designs for sensor integration as an assembly process

 Cavities for placement of sensors

 Implementation of fasteners or caps

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Objective 3: Testing of the EBM fabricated Low-NOx fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory Turbine Combustor

Task 2.1: Powder removal for internal channels

 methods for powder removal to be explored include, but are not limited to, dry ice blasting, ceramic blasting, water jetting, chemical etching, ultrasonics, and megasonic baths

 3 parts of each sized cavity will be fabricated and tested with each method

Task 2.2: Powder removal for internal cavities

 To determine the appropriate number of outlets and outlet size that allow improved powder removal

Task 2.3: Process parameter modifications for improved optimal powder sintering

• To change the heat input to the sintered powder which consists of changing parameters such as beam speed, beam power, and beam focus.

• An improved parameter set would allow for the powder bed to become more or less sintered and easier to remove via the pow